Forklift Safety
Powered industrial trucks are the single largest source of fatalities in warehousing. OSHA's standard (29 CFR 1910.178) requires that every forklift operator be trained and evaluated before operating a powered industrial truck, with documentation on file. Refresher training is required after any unsafe incident, evaluation showing unsafe performance, or assignment to a different truck type. Daily pre-operation inspections must be logged. Pedestrian traffic must be separated from forklift operating areas through marked lanes, barriers, or procedural controls.
Loading Dock Safety
Loading docks present fall hazards, struck-by hazards from trailers, and dock-plate hazards. Key requirements: dock levelers and plates must be rated for the loads placed on them and maintained in safe condition. Trailers must be chocked or restrained before workers enter to load or unload. Dock edges above 4 feet require fall protection. Workers must never stand beneath suspended loads.
Ergonomics and Manual Material Handling
Musculoskeletal injuries from lifting, reaching, and repetitive motion are the most common warehouse injuries. While OSHA has no specific ergonomics standard, the General Duty Clause applies to recognized ergonomic hazards. Use mechanical assists (pallet jacks, conveyors, lift tables) to reduce manual lifting. Establish maximum lift weights and team-lift procedures. Rotate workers through repetitive tasks.
Walking and Working Surfaces
Warehouse floors must be kept clean and free of debris. Aisles must be clearly marked and maintained at minimum widths. Floor load ratings must be posted and observed. Storage racking must be rated for stored loads, inspected regularly, and repaired or removed from service when damaged.
Hazardous Materials
Warehouses that store hazardous materials must comply with OSHA's HazCom standard and, in many cases, EPA and DOT requirements as well. SDS must be available for all hazardous materials on site. Workers who handle hazardous materials must be trained. Incompatible materials must be segregated. Spill response equipment and procedures must be in place.
Required Written Programs
- Hazard Communication Program
- Emergency Action Plan
- PPE Hazard Assessment
- Lockout/Tagout Program (for equipment maintenance)
- Hearing Conservation Program (if noise exposures apply)